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specially designed twin screw expander to generate electricity in small-scale projects utilizing hot water in the 190–240F (88–116C) range. The company deployed its 3050 model, with an output of 30– 50kW, in a number of demonstration applications, including electricity generation from waste heat from a boiler at a university and two microconcentrating solar power projects. In 2011, the company expanded the range of power output with its Series 4000 Green Machine to 30–65kW. The Green Machine's small footprint, at 5 x 5ft, enables it to be located close to a waste heat source in a commercial or industrial building, and by productizing the unit, the company should be able to take advantage of economies of scale once volumes pick up. However, capital costs for the units can be a bit high, at $2.50/W to $4/W, and the company has yet to deploy a substantial number of commercial units. Ener-G-Rotors Ener-G-Rotors, headquartered in Rotterdam, New York, is developing a unit that converts hot water or low gauge steam, in the 150–300F (65–149C) range, to electricity in small-scale projects. The technology is centered around a new expander, the trochoidal gear engine, which replaces the turbine in a traditional organic Rankine cycle. The company is finalizing the development of its GEN4 model, which it hopes to deploy in trials in late 2011 and launch commercially in 2012. The units will have an output of 40–60kW. Ener-G-Rotors states that the units will have a 20-year life, with little to no maintenance and, under the right circumstances, will be able to produce electricity at prices as low as $0.015/kWh without government incentives. Conclusions The waste heat to power industry continues to have great potential to produce significant amounts of clean energy in the United States, but progress in the industry has been slow, and growth has been almost nonexistent. Projects are getting built here and there, but the industry is not seeing the rapid growth experienced by wind and solar in recent years, despite its credentials as, at best, a renewable source of energy, and at worst, a source of energy efficiency improvements. Local and state incentives help, but only to the extent that the regions in which they are implemented overlap with substantial waste heat resources. Federal incentives are lacking, and their adoption at levels seen for renewables, (i.e., grants or tax rebates for 30% of project capital costs) would provide a significant boost to the industry. Unfortunately, those incentives are not likely to materialize soon. New business models that reduce risks for waste heat hosts while optimizing technology selection and financing terms seem to have the ©2011 IDC Energy Insights #EI229456 Page 9PDF Image | Waste Heat to Power Still Waiting for a Breakthrough
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